Metal Additive Manufacturing (AM) has been on the rise in recent years. In 2023, the sales of metal AM systems reported a 24% increase compared to the previous year, significantly outpacing the overall AM market growth of 11.1%. This surge underscores a growing focus on metal applications within the industry.
One of the key players driving this growth is Bright Laser Technologies (BLT), a Chinese-based AM company valued at USD 1.8 billion (as of June 2024) on the Chinese stock exchange. At Formnext 2024, I had the opportunity to visit their booth and witness their remarkable progress firsthand.
Company background
The world’s first metal 3D printer was introduced in the mid-1990s by EOS, marking the dawn of commercial metal additive manufacturing. At the time, the technology was expensive and primarily designed for manufacturing applications, which slowed its adoption as users explored its potential in design and production processes.
Over the years, only a handful of metal AM manufacturers entered the market. Among them was Bright Laser Technologies (BLT), founded in China in 2011. BLT set out with a clear mission: to provide end-to-end solutions that would enable users to scale metal AM for full production.
Leveraging metal laser powder bed fusion (PBF-LB/M) technology, BLT developed an integrated ecosystem comprising industrial 3D printers, dedicated software, and specialized materials—all synchronized and optimized for seamless workflows.
In addition to its hardware and software innovations, BLT established a dedicated 3D printing services division. This business unit allows users to explore metal AM applications without the need to invest in equipment upfront. BLT has focused on serving industries such as aerospace, automotive, energy, molding, and medical, with applications ranging from custom aerospace components to industrial tooling and medical.
BLT HQ facility in Xi'an City, Shaanxi Province, China. Image source: BLT Ltd.
The IPO and the Big Break
In 2019, Bright Laser Technologies (BLT) went public on the Chinese stock market to raise additional funds for accelerating its business expansion. Following consistent quarter-on-quarter growth, the company’s stock skyrocketed, increasing fivefold within just two years of its IPO.
With a well-executed go-to-market strategy, BLT successfully expanded its market share in China, selling hundreds of industrial 3D printers to a range of industrial users.
Additionally, the company’s 3D printing services division evolved into a full-scale production facility, housing over 350 units. This facility produces hundreds of parts daily using a variety of advanced materials, such as titanium and aluminum alloys, as well as stainless steels.
Beyond contributing to a fast-growing revenue stream, this division plays a pivotal role in advancing BLT’s technology. By working closely with industrial users to develop new applications, BLT has been able to accelerate the development of its 3D printers, consistently incorporating user feedback and acquired expertise into its products.
BLT offers customers seeking to integrate metal additive manufacturing (AM) into production a full ecosystem of hardware, software, and materials. Beyond the technology itself, BLT provides deep expertise in designing for additive manufacturing, identifying suitable applications, and offering tools to calculate the return on investment (ROI) for an industrial metal AM system.
In 2023, BLT reported annual revenues exceeding USD 170 million from its solutions and services. With a current market capitalization of USD 1.8 billion, BLT has solidified its position as the largest company in the metal AM industry.
BLT at Formnext 2024
At Formnext 2024, BLT unveiled the upgraded BLT-S450, an advanced metal AM system specifically optimized for serial manufacturing. The latest upgrades enhance efficiency, reliability, intelligence, and cost-effectiveness, making the BLT-S450 a versatile solution for industries such as aerospace, automotive, tooling, and consumer electronics.
The BLT Team at Formnext 2024. Image source: BLT Ltd.
In addition, BLT highlighted the versatility of its technology through groundbreaking applications across several industries. Here are the ones that stood out:
Aerospace Application – the Array Panel
One of the most impressive exhibits at the BLT booth was a 3D-printed array panel, manufactured using the BLT-S1000 large-scale 3D printing system. This specialized component serves as the carrier for radiating elements in array antennas and was assembled on the SmartSat-2A Satellite, which launched earlier this year. The panel demonstrates how BLT’s technology meets the rigorous demands of aerospace applications, showcasing precision, lightweight structures, and unique design capabilities.
This amazing 1125mm × 20mm × 1300mm element was printed from aluminum alloy, designed with a unique lattice structure to ensure rigidity while significantly reducing weight. With a minimum wall thickness and strut diameter of just 0.5mm and an overall dimensional tolerance of ±0.5mm, this component highlights BLT’s advanced technology and its capability to produce demanding, precision-engineered parts for industrial use.
The 3D printed Array Panel presented at Formnext 2024. Image source: BLT Ltd.
Automotive Application – the Rear Subframe
Electric vehicles (EVs) are predominantly designed from scratch, unbound by traditional car models. This clean-slate approach has made Additive Manufacturing (AM) a critical enabler for developing lightweight components, testing designs prior to mass production, creating jigs and fixtures for assembly, and manufacturing customized parts.
At the show, BLT unveiled a groundbreaking 3D-printed rear subframe measuring 1230mm x 845mm x 253mm. Its design features an optimized topology achieved through Bidirectional Evolutionary Structural Optimization (BESO). Weighing just 21kg, the subframe is 20% lighter than the original die-cast aluminum version, thanks to a 2mm-thick hollow lattice structure that eliminates the discontinuities associated with traditional manufacturing processes.
BLT also showcased additional automotive components, including steering knuckles and battery brackets, specifically tailored for Western markets. These innovative parts offer significant benefits such as reduced weight, shorter production cycles, and lower costs.
These remarkable elements underscore the power of Metal Laser Powder Bed Fusion (PBF-LB/M) AM technology, demonstrating its ability to meet the stringent requirements of advanced, high-performance automotive applications.
The Aluminum Alloy EV rear subframe. Image source: BLT.
Scaling Manufacturing of Battery Housing
Thanks to their large build volume, BLT Metal AM systems are well-suited for producing small-to-large batches of components for functional testing and end-use parts. The process begins with topology optimization to reduce weight, followed by carefully designed tray setups to maximize efficiency and minimize support structures. Pairing this approach with the right material—in this case, BLT’s Ti64 titanium alloy—and leveraging a robust technology ensures high standards of quality, accuracy, and repeatability.
Full-scale metal AM production of end-use parts. Image source: BLT.
Leading the Metal Industrial Revolution
BLT is strategically positioned to lead the global metal digital manufacturing revolution. With over 1,700 employees, including 500 dedicated to R&D, a strong financial foundation, and over 1,000 installations worldwide, the company is well-equipped to continue its global expansion. Its balanced revenue streams from both AM system sales and AM services further reinforce its robust growth trajectory.
BLT Europe, covering the EMEA region with six partners and a growing in-house team, have busy days ahead. In just 12 months, they have tripled the EMEA install base and their team members. Next year, the company has several installations in the pipeline. BLT Europe is also expanding their reach in 2025 with more partners in strategic regions. They are also adding more manpower into technical sales and service.
A key strength of BLT lies in its singular focus on metal laser powder bed fusion (PBF-LB/M) technology, which it supports with advanced software tools, a wide range of materials, and post-processing solutions. This integrated, end-to-end platform streamlines manufacturing processes, making it more accessible to a variety of industries.
Moreover, the company offers its products at competitive pricing compared to Western AM companies, significantly lowering the barrier to entry for manufacturers exploring digital manufacturing. This affordability enhances the ROI calculation for businesses considering adopting metal AM technologies in their production processes.
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